• Journal of the Korean Society for Precision Engineering
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• v.13 no.5
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• pp.84-94
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• 1996

In order to prevent shell sticking by providing sufficient lubrication between the strand and the mold, the mold oscillation has been used. Now it is well known that the shape of the oscillation curve has a decisive effect on the surface quality of the cast product. Besides, oscillation parameters such as stroke and frequency are also very important. In order to guarantee that parameters which have been found to be optimal for a certain grade of steel do not change with time, periodical checks of the physical condition of the whole equipment are necessary. The portable mold oscillation analyzer with integrated computer, developed by POSCO, records the movement of the mold in every spatial direction. The system uses the gap sensors to measure the mold movement (displacement ) in the two horizontal directions according to the mold narrow and broad faces and the vertical strokes in the four corners of mold. The gap sensor is a non-contacting minute displacement measuring device using the principle of high frequency eddy current loss. The mold oscillation diagnosis system integrates the gap sensors, their converters and the industrial portable computer with plug-in data acquisition boards. The all programs, such as the fast Fourier transformation module (amplitude and phase spectrums) and harmonic analysis module, was coded by LabVIEW$^{TM}$ software as the graphical language. In an own 'expert module' which is included in the diagnosis program, one can obtain much information about the mold oscillation equipment.

• Composites Research
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• v.15 no.1
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• pp.32-40
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• 2002

This study developed fabrication process of $SiC_p/Al$ metal matrix composites as electronic packaging materials by squeeze casting method. The $SiC_p$ preform were fabricated in newly designed preform mold using about 0.8 % of inorganic binder(SiO$_2$) and 5 vol.% of $Al_2O_3$fiber. To infiltrate the molten metal into the preform, fabrication condition such as the temperature and the pressure were selected. Applying the fabrication conditions, heat transfer analysis were preformed using finite element method and thus analyzed the temperature distribution and cooling characteristic during the squeeze casting. For the fabricated composites, impact toughness and thermal expansion coefficient were measured. The metal matrix composites developed in this study have 0.2~0.3 J impact toughness, $8~10 ppm/^{\circ}C$ thermal expansion coefficient and $2.9~3.0g/cm^3$density which is appropriate properties for electronic packaging application.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.26 no.6
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• pp.1120-1126
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• 2002

Machining characteristics of tool steels manufactured by electro slag casting process has been investigated in this study. For the estimation of machinability, turning and drilling tests are carried out. The chip shapes at various velocities are investigated for the comparison of turning workabilities of tool steels because the chip shapes reflect characteristics of cutting resistance. In case of drilling test, feed motor currents measured by a hall sensor are used as a measure for the drilling resistance. The machining characteristics of the tool steels are strongly correlated with tensile properties, such as tensile strength, hardness, and ductility. In case of turning workability, it was found to be favoured by the higher tensile strength, while the opposite is true far the drilling workability. The electro-slag casted materials show better turning workability in the viewpoint of chip shapes and, the quenching-tempered electro-slag casted material has relatively better drilling machinability than that of the annealed one.

• Journal of the Korean Society for Precision Engineering
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• v.16 no.6
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• pp.36-44
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• 1999

The rapid Tooling technique is classified into two methods: one to directly utilize the model which was made by rapid prototyping technologies for dies, and the other to make a transferred type using the model as a master model and create dies and molds using it. In this study, the Al powder filled resin was made several mixed ratios and meshes sizes, and applied to slurry casting. And, variation of mechanical characteristics such as the shrinkage rate, the tensile strength, the elongation, the hardness, and surface roughness, are measured to compare. Consequently, as higher is the powder mixed ration and as smaller is the grain size of the power, the mechanical characteristics of the final mold are improved. Finally, the metal short fiber which can be fabricated easily and cheaply, if the self-excited vibration of an elastic tool, was also applied to slurry casting. It has been found tat the hardness gets higher, while the shrinkage rate lower, if mixed with short fiber.

• Transactions of Materials Processing
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• v.19 no.6
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• pp.378-386
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• 2010

Nowadays there has been great interest in using heat treated cast material for press dies due to several advantages like reduction in die production costs. However, in hot press forming processes H13 forged tool steel is mostly used. Cooling performance of dies in hot press forming processes is considered as an important factor of study and also the IHTC parameter between cast material die and sheet metal should be considered as an essential. In the present study, the IHTC was calculated for the sheet metal in the hot press forming process with cast and forged material dies. The temperature measurements were performed for the sheet metal, casting and forged material dies by applying various contact pressure in hot press forming. IHTC was calculated and studied by adopting the inverse heat convection method in DEFORM-2D. Each IHTC was considered as a function of contact time and contact pressure. The experimental data were compared with calculated data obtained from the proposed equation and references.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.21 no.3
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• pp.576-584
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• 2020

The extruder screw material is mainly SKD11, but the recent development of synthetic resins have increased the occurrence of chemical corrosion and wear. To solve this issue, high chromium cast iron is needed because of its good abrasion resistance and corrosion resistance, but its use is avoided because of its poor machinability. In this study, to improve the machinability of high chrome cast iron, 0, 0.5, 1.0, 1.5% of nickel, which has excellent workability, was added to high chromium cast iron with a composition of Fe-23Cr-2.5C-1.2Si-1.08Mn-0.48Mo-0.3V, and annealed after casting. Subsequently, the effect of nickel on the machinability and corrosion resistance was analyzed using a turning test and coin polarization test, and compared with SKD11. After casting using a high-frequency vacuum induction furnace, the annealing treatment was performed at 750 ℃ for five hours and then reheated at 1100 ℃ for five hours. A turning test after annealing at 750 ℃ showed that the machinability was improved remarkably when the nickel content was over 1.0%. In the potentiodynamic polarization test in a 5% NaCl solution, the corrosion resistance decreased with increasing nickel content in the as-cast and annealing treatment. On the other hand, after reheating, the corrosion resistance was best with a 1.5% nickel content.

• Korean Journal of Materials Research
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• v.11 no.12
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• pp.1028-1034
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• 2001

The 2.5 vol% TiNi/6061Al composites were fabricated by permanent mold casting. The microstructures and tensile test for the cold rolled composites with maximum 50% reduction ratio were investigated. In the case of TiNi fiber with 2mm interval in preform, the interface bonding of fabricated composites were good, interface diffusion layer of this composites was made by the mutual diffusion. Transverse section of TiNi fiber was decreased with increasing reduction ratio and longitudinal section of TiNi fiber showed multiple wave phenomenon. And the tensile strength of composites at 38% reduction ratio was the most high. In the case of over 38% reduction ratio, the decrease of the tensile strength was due to TiNi fiber rupture by excess working. The fracture mode was appeared brittle fracture with increasing reduction ratio.

• Transactions of the Korean Society of Mechanical Engineers A
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• v.34 no.7
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• pp.905-910
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• 2010

Exhaust manifolds are the first structures to be developed by hydroforming; mass production of exhaust manifolds by this method will be possible soon. This is obviously related with tight emission regulation induced by environmental problems commonly for both domestic and worldwide and standards, thus evoking its solution for domestic automakers. Compared to conventional cast products, thin-gauge tubular hydroformed exhaust manifold have superior features; for example, in the hydroformed exhaust manifold, gas decomposition during the cold-start period of the engine is reduced by lowering the heat sink, and manufacturing process is simplified since less welding is involved. The aim of this study is to develop a hydroformed exhaust manifold; the study deals with the components, the hydroforming process, and tool design of the manifolds. The performance of the exhaust system is evaluated by performing flow analysis, heat-transfer analysis, heat-stress analysis, and fatigue analysis by using a computer.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.16 no.5
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• pp.2993-2999
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• 2015

Steel companies are applying Ni-B or Ni-Co alloy plating to protect the surface of Continuous casting mold, and they are using saccharin polish which causes crack on plating layer due to sulfur in saccharin. It is considered that the Ni-S compound causes the cracking and additional tensile stresses. The Ni-Mn-B ternary alloy plating was developed for suppression of crack by forming Mn-S compound before Ni-S compound is formed, but there were no domestic or international standard on the Ni-Mn-B alloy plating. Therefore, reliability evaluation standard was established to evaluate the newly developed Ni-Mn-B plating. To develop accelerating life testing method, FMEA(Failure Mode & Effective analysis) was used to analyze the cause of the main failure in plating. The Ni-Mn-B reliability standard included accelerating life test method, and it was categorized by the fundamental performance test, environment test, and accelerated life test, and was designed to guarantee 1 000 hours of B10 life with 80 % reliable level.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.22 no.2
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• pp.593-601
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• 2021

The axial fan is an element of a blower used for ventilation in various industrial fields. Many studies on aerodynamic performance have been conducted to assess axial fans using fluid dynamics. The subject was a large axial fan size, 1800 mm in diameter with 100 horsepower. The blower's axial fan consisted of blades, hubs, hub caps, and bosses are important components. The blade design has a great influence on the aerodynamic performance. 3D point data is extracted using an aerodynamic performance prediction program, and a 3D modeling shape is generated. The blades and hubs, which are important components, can be easily modified if processed by cutting owing to the environment in which blades and hubs are manufactured through die casting or gravity casting. In this study, the structural safety of components and the analysis results of weak areas at the rated operating speed of the axial fan were verified using the maximum stress and safety factor. The tip clearance reflected in the design was the rotation of the blade. To check whether there is interference with other components, the displacement result was derived to verify the structural safety of the axial fan.